scheduled/special inspections & recommended support parts · 2013-05-28 · scheduled/special...

Scheduled/Special Inspections & Recommended

Support Parts

SPECIALTY HAULAGE SOLUTIONS FOR CONSTRUCTION AND MINING

MEGA CORP.®700 Osuna Rd. N.E. • Albuquerque, NM 87113 • 1-800-345-8889 • 505-345-2661 • Fax 505-345-6190

www.megacorpinc.com® MEGA Corp., Inc. All Rights Reserved

MSC/MST-INSP-RSP-5

MSC/MST-INSP/RSP-5 7 Nov 2012

TABLE OF CONTENTS

A

Page

Section 1. Definitions & Abbreviations …………………………………………………. 1-1

Section 2. Scheduled Inspections ………………………………………………………... 2-1

Section 3. Special Inspections …………………………………………………..………. 3-1

Section 4. Recommended Support Parts ………………………………………………… 4-1


TABLE OF CONTENTS

B(Blank)


SECTION 1 Definitions and Abbreviations

Contents

1-1

Manual Usage ……………………….. 1-1

Warning, Cautions & Notes ………..... 1-1

Shall, Will, Should and May ..………. 1-1

Safety Messages .........……………..….. 1-2

Abbreviations ………………………..… 1-5

MSC/MST Overview …………….…..… 1-6

MANUAL USAGE This technical manual only contains information

required to safely install or service an

MSC/MST. See the appropriate Maintenance

and Operators Safety Manual for specific vehicle

system information and maintenance procedures.

The exact location of the hazards and description

of the hazards are reviewed in this section. All

personnel working on or operating the

MSC/MST must become familiarized with all

the safety messages.

If your system is not covered in this manual

please contact the MEGA Corp. Product Support

Group at:

US toll free: 1-800-345-8889

Direct: 1-505-345-2661 or visit our website at

www.megacorpinc.com for more detailed

contact information.

See the proper manufacture specific Operation &

Maintenance, Safety Manuals and Service

Manuals for detailed chassis specific system

information and chassis specific maintenance

procedures.

Due to the nature of these processes, ensure that

all safety information, warnings and instructions

are read and understood before any operation or

any maintenance procedures are performed.

Some procedures take place with heavy

components and at moderate heights, ensure

proper safety procedures are maintained when

performing these actions. Failure to use and

maintain proper safety equipment and procedures

will cause injury, death or damage to equipment.

WARNING, CAUTION AND NOTES The following definitions are found throughout

the manual and apply as follows:

Operating procedures and techniques, which

could result in personal injury and/or loss of life

if not carefully followed.

Operating procedures and techniques, which

could result in damage to equipment if not

carefully followed.

Operating procedures and techniques that are

considered essential to emphasize.

USE OF SHALL, WILL, SHOULD

AND MAY Shall and Will – Used when application of a

procedure is mandatory.

Should – Used when application of a procedure

is recommended.

May - Used to indicate an acceptable or

suggested means of accomplishment.

http://www.megacorpinc.com/



1-2

SAFETY MESSAGES There are several specific safety messages on

this machine. The exact location of the hazards

and description of the hazards are reviewed in

this section. All personnel working on or

operating the machine must become

familiarized with all the safety messages.

Make sure that all of the safety messages are

legible. Clean the safety messages or replace

the safety messages in you cannot read the

words. Replace the illustrations if the

illustrations are not legible. When you clean

the safety messages, use a cloth, water and

soap. Do not use solvent, gasoline or other

harsh chemicals to clean the safety messages.

Solvents, gasoline or harsh chemicals could

loosen the adhesive that secures the safety

messages. Loose adhesive will allow the safety

messages to detach.

Replace any safety message that is damaged or

missing. If a safety message is attached to a

part that is replaced, install a new safety

message on the replacement part.

Toxic Gas Hazard (1)

This safety label is located on the side of the

tank and at all water fill entrances.

Cutting or welding operation on the inside of

the tank can cause the accumulation of toxic

gases. Read and understand instructions and

warnings in the Maintenance Manual.

Failure to provide proper ventilation or

breathing apparatus while conducting these

operations may result in serious injury or

death.

Do Not Operate (2)

This safety label is located on the outside of the

front and rear control boxes. (If equipped)

Do not open this control box unless you read

and understand the instructions and

warnings in the Operator and Maintenance

Manual. Failure to follow instructions or

heed the warnings could result in serious

injury or death.



1-3

Backing Runover Hazard (3)

This safety label is located on the rear of the

tank and inside the cab.

The vehicle is equipped with a back-up

alarm. Alarm must sound when operating

this vehicle in reverse. Failure to maintain a

clear view in the direction of travel could

result in serious injury or death.

Freezing (4)

This safety label is located on the side of the

tank, at the sump drain, and on the pump.

Drain tank, fill pipe and valve in freezing

weather. Refer to the Operator and

Maintenance Manual for the procedure to

follow.

Non-Potable (5)

This safety label is located on the side of the tank

and sump drain.

Water held within tank is not potable. Do not

use tank for transport of water intended for

human or animal consumption or serious

injury or death may result.

Do Not Hoist While in Motion (6)

This safety label is located inside the cab.

Do not engage hoist cylinders while vehicle is

in motion. Before engaging hoist STOP the

vehicle. Do not engage hoisting cylinders

unless you read and understand the

instructions and warnings in the Operator or

Maintenance Manual. Failure to follow

instructions or heed the warnings will result

in injury or death.



1-4

Fall Hazard (7)

This safety label is located at the top of the front

and rear of the tank.

Do not walk on the top of tank without fall

arrest PPE. Serious injury or death could

occur from a fall.

Rotating Shaft (8)

This safety label is located on the pump.

Do not place your hand or tools within pump

bell while pump is rotating and/or pressure

held within the motor supply hose. Refer to

the Operator and Maintenance Manual for

the procedures to operate and maintain the

pump. Failure to follow proper procedures

could result in serious injury.

High Pressure Sprayheads (9)

This safety label is located on the spraybar.

Do not operate sprayheads until all personnel

are a safe distance away from the vehicle.

High Pressure Monitor (10)

This safety label is located on top of the cab

control box.

Do not operate the monitor until all personnel

are a safe distance away from the vehicle.



1-5

High Pressure Motor (11)

This safety label is located on the hydraulic

motor.

Hydraulic motor and supply lines contain oil

under high pressure. Improper removal and

repair procedures could cause severe injury.

To remove or repair, instructions in the

Maintenance Manual must be followed.

Confined Space (12)

This safety label is located near water tank

access and fill ports.

Do not enter confined spaces without

following established site specific procedures.

Failure to follow proper safety procedures

will result in serious injury or death.

ABBREVIATIONS

BFV – Butterfly Valve

cc – Cubic Centimeters

CCW – Counter Clockwise

CW - Clockwise

fl. oz. – Fluid Ounce

FT - Feet

FPM – Feet Per Minute

GPM – Gallons Per Minute

IN/SQ FT – Inches per Square Feet

KM-H – Kilometers Per Hour

Kg – kilograms

Kpa - Kilopascals

l – liters

lpm – Liters per minute

LT – Left as viewed from the operators

position facing forward

m - meters

MPH – Miles Per Hour

MSC/MST – Mega Scraper Conversion

Nm – Newton meters of torque

psi - pounds per square inch

QCC – Quick Change Component

RPM – Revolutions Per Minute

RT – Right as viewed from the operators

position facing forward

SQ FT – Square Feet

VDC – Volts, Direct Current



1-6

REAR

VIEW

SIDE

VIEW

1

3 3

3

1 2

4

WATER PUMP& HYDRAULIC MOTOR

HOSE REEL

SPRAY HEADS

CAB CONTROL

MSC/MST Overview (Typical)

8 SOLENOID BOX

5

6

7

HAND RAIL & WALKWAY

FOAM CONCENTRATE TANK

MONITOR

2

4 5

6

7

5 8


SECTION 2 Scheduled Inspections

2-1

DESCRIPTION This section establishes scheduled maintenance inspections of the installed MSC/MST at the

designated frequencies. Performing these inspections will identify potential system discrepancies and

allow preventative maintenance to be performed before a component or system is rendered totally

inoperative.

** NOTE: Vehicles operated in extremely low quality water environments may require more frequent

inspections.

FREQUENCY

STEP SPRAYHEADS

150 HRS (WEEKLY)

250 HRS (BI-WEEKLY)

500 HRS (MONTHLY)

1000 HRS (QUARTERLY)

5000 HRS (ANNUAL)

1 Check spray head for damage and clean deflector ring and spray head opening. X

2 Check hydraulic lines for security, damage and leaks. Repair as required. X

3 Check spray head base plate and upper housing mount bolts for security. X

4 Check spray head adjustable deflector ring for damage and correct adjustment. Apply dry-film lubricant to the deflector inner ring.

X

5 Check spray head base plate for evidence of leaks. Replace base plate O-ring as required X

6 Check spray head drop-in assembly for leaks with spray head switch OFF and water pump ON. Replace drop-in assembly as required.

X

FREQUENCY

STEP CONTROL SYSTEM

150 HRS (WEEKLY)

250 HRS (BI-WEEKLY)

500 HRS (MONTHLY)


5000 HRS (ANNUAL)

1

Check all electrical cables for security and damage. Clean and inspect Deutsch connectors while ensuring all silicone gaskets are in place and serviceable. Repair as required.

X

2 Check all hydraulic solenoids and hosing for security and leaks. Repair as required. X

3 Check monitor/nozzle assembly for security leaks and condition. Repair as required. X

4 Check foam agent supply hoses and shut-off valve for security condition and evidence of suction leaks.

X

5 Check hose reel for security mounting and leaks. Repair as required. X

6 Unreel the entire length of hose, pressurize hose and check hose and nozzle for security, wear and leaks. Repair as required.

X

7 Check all in-cab control functions for proper operation. Repair and replace control components as required.

X


SECTION 2 Scheduled Inspections

2-2

STEP MSC/MST STRUCTURE

150 HRS (WEEKLY)

250 HRS (BI-WEEKLY)

500 HRS (MONTHLY)


5000 HRS (ANNUAL)

1 Check filler port trash screen for debris and inspect assembly for security and damage. Repair or replace trash screen as required.

X

2 Visually inspection tank exterior for damage and evidence of leaks. Repair as required X

3 Drain tank and remove water pump sump access cover. Remove trash and inspect sump area for damage.

X

4

Check all interior tank structure for leaks, cracks and condition of interior epoxy coating (if equipped). Repair structure and coatings as required.

5 Check all lights (turn signal, brake, backing, parking, clearance and work) for proper operation. Replace bulbs as required.

X

6

Check gooseneck and attaching points for cracks, security and damage. Inspect for hydraulic and fuel leaks. Hoses and wiring for security damage and leaks.

X

7

Check the bogie structure for any cracking. Close attention should be paid to all gusseting, as well as to the wheel group mounting plates. Repair structure as required.

8

Check all components on the bogie for leaks and/or damage. These components include air tanks, air lines, brake pods, hydraulic connections, spray bar, dump bar, and wheel groups. Repair or replace as required.

X

STEP WATER PUMP SYSTEM

150 HRS (WEEKLY)

250 HRS (BI-WEEKLY)

500 HRS (MONTHLY)


5000 HRS (ANNUAL)

1

Remove water pump from unit and check: water pump impeller retaining bolt/nut for security and for damage or contact to the impeller, impeller keyways for wear and security, shaft bearings for signs of heating and wear, drive end shaft keyways for signs of damage and heating and seals for security, damage and over or under lubrication. Check volute case for damage or contact. Check both of the impeller wear rings for damage and excessive wear (0.020” or 0.5 mm nominal tolerance) Check packing mount for security. (Disassembly of water pump is required to perform these maintenance operations). Repair as required.

X

2

Check shaft seals for excessive lubricant leakage and water leakage. Lubricate water pump with a manual grease gun only. When lubricating the drive motor side shaft bearing apply only 16 to 20 squirts (injections) of grease (2 fl. oz. or 60 cc) and 8 to 10 squirts (injections) of grease (1 fl. oz. or 30 cc) to the impeller end bearing. Apply 4 or 5 squirts (injections) of grease to lantern ring grease fitting. Adjust, repair or replace as required.

X


SECTION 2

Scheduled Inspections

2-3

STEP

WATER PUMP SYSTEM

150 HRS (WEEKLY)

250 HRS (BI-WEEKLY)

500 HRS (MONTHLY)


5000 HRS (ANNUAL)

3 Check water pump and drive motor for leaks, excessive vibration/noise leaks and evidence of excessive heating. Repair as required.

X

4

Check rope seals for excessive water leakage, compression, wear and overheating. Adjust rope packing seal packing gland or replace rope packing seals as required.

X

5 Check water pump inlet and discharge piping for security, leakage and misalignment. Repair leaks as required.

X


SECTION 2

Scheduled Inspections

2-4Blank)


SECTION 3 Special Inspections

3-1

DESCRIPTION This section contains special inspection

requirements for a specific system after use, an

unusual event or storage.

FIRE SUPPRESSION SYSTEM

After Use 1. Flush foam concentrate supply hose,

monitor and nozzle with fresh water.

2. Inspect foam concentrate hose for signs of

collapsing, kinks, wear or leaks.

3. Wash down all MSC/MST and vehicle

surfaces that were exposed to the foam or

foam concentrate.

STORAGE/WINTERIZATION

Entering

1. Remove any exterior dirt, grease and grime

that may trap moisture.

2. Flush all water suction and discharge lines

(e.g. water pump, spray heads, monitor,

dump bar and hose reel).

3. Ensure all water is drained from the

MSC/MST.

4. (If equipped) Fully extend hose reel and

ensure nozzle and hose are fully drained of

water.

5. Remove lowest drain plugs on the water

pump and the MSC/MST. Ensure all

suction and discharge lines are drained.

6. (If equipped) Inspect MSC/MST interior

epoxy coating for wear.

7. Prime and paint any exposed metal.

8. Seal all fill and discharge openings to keep

foreign matter out (e.g. dirt, dust, insects,

rodents and water).

9. Lubricate the water pump and any other

MSC/MST component that require grease.

10. Service all vehicle systems per prime

mover service manual.

11. If possible, shelter the pump assembly from

the elements.

12. Check to ensure all MSC/MST solenoid

and junction boxes are closed and secure.

13. If possible, shelter entire vehicle from the

elements.

Removing 1. Remove all covers and seals from all

MSC/MST fill/discharge openings and

components.

2. Inspect interior of the tank for any foreign

matter and condition of epoxy coating (if

equipped).

3. Check to ensure all water pump and

MSC/MST drain plugs are installed.

4. Remove any exterior dirt, grease and grime

and treat any corrosion.

5. Service all vehicle systems per prime

mover service manual.

6. Fill MSC/MST with water and inspect the

systems for leaks.

7. (If equipped) Perform a functional check of

the hose reel.

8. Perform a full functional check of all

MSC/MST cab controls systems.


SECTION 3 Special Inspections

3-2Blank)


SECTION 4 Recommended Support Parts

4-1

DESCRIPTION This section contains a listing of recommended support parts that should be available in the supply

warehouse. Several support parts are designated as a “Quick Change Assembly” and should be used to

minimize repair time of an operational tanker. The broken assemblies can then be returned to the

maintenance for repair and eventually returned to the supply warehouse as a serviceable part. Once

parts are issued from warehouse stock ensure depleted quantities are replenished to keep the

recommended support parts package at 100%.

The tables are categorized by specific sub system of the MSC/MST. DO NOT FORGET that all

MSC/MSTs are not configured the same and there are several variations in water pumps, hydraulic

drive motors and monitors due to changes in equipment and actual production dates. Ensure

MSC/MST serial numbers and actual component part numbers are checked before ordering any parts.

A. SPRAY HEAD PARTS GROUP (PNEUMATIC)

PART DESCRIPTION PART NO. QTY

1. Spray Head Drop-in Assembly 300409 6

2. Diaphragm 300208 18

3. Guide Disk, Lower 300209 2

4. Guide Disk, Upper 300210 2

5. Bolt, Stem 300211 2

6. O-Ring, Stem Bolt 300215 4

7. Nut, Stem 300214 2

8. Bell Washer 300212 2

9. Spring 305304 6

10. Cap Screw, SS, Housing 355335 16

11. Washer, Lock, SS, Housing 355337 16

12. Washer, Flat, SS, Housing 355336 16

13. Adjusting Ring 300216 6

14. Knob, Adjusting Ring 302912 6

15. O-Ring, Base 354502 16

16. Washer, Flat (Base Plate Mount) 355295 8

17. Cap Screw 355294 8

18. Hydraulic Spray System **MSC/MST Serial No. Specific Part

a. (STD) Hydraulic Spray Head Assy. (Quick Change Component) 025610 2

b. Cylinder, Hydraulic 304744 2

c. Nut, Hex 1/2 x 20 350044 4

d. Spring 305304 1

19.Pneumatic Spray System **MSC/MST Serial No. Specific Part

a. Pneumatic Spray Head Assy. (Quick Change Assembly) 300198 2

b. Valve, Release 300468 2

c. Spring 300213 1



4-2

B. CONTROL SYSTEM PARTS GROUP


1. Joystick, Universal **MSC/MST Serial No. Specific Part 303041 1

2. Timer, Intermittent **MSC/MST Serial No. Specific Part 304751 1

3. Switch, SPST, Green Lens (Cab Control) 305019 2

4. Switch, SPST, White Lens (Cab Control) 305020 1

5. Switch, DPDT, No Lens (Cab Control) 305021 1

6. Sensor, Water Level ** MSC/MST Serial No. Specific Part

a. Units with Water Level Volume, <120 inches 303822 1

b. Units with Water Level Volume, >120 inches 304414 1

7. Hydraulic Spray System ** MSC/MST Serial No. Specific Part

a. Solenoid Valve, Hydraulic (Solenoid Box) 305156 2

b. Coil, 24 VDC with Connector 305590 2

c. Filter Element (Solenoid Box) 305276 1

d. Repair Kit, Hydraulic Filter (for Filter Assy. 305277)

8. Pneumatic Spray System ** MSC/MST Serial No. Specific Part

a. Solenoid Valve, Pneumatic (Spray Head Valve) 304929 1

b. Solenoid Valve, Pneumatic (Butterfly Valve) 304948 1

C. DIGITAL SPRAY SYSTEM CONTROL

NOTE: (Serial No. & Software Revision Required)


1. Switch Box Enclosure 306401 1

2. Fuse, Blade 10 Amp (Switch Box Power) 306524 1

3. Joystick Box Enclosure 306402 1

4. Joystick, Universal 303041 1

5. Cable 6’, 18 Gauge, Joystick to Switch Box 046057 1

6. Cable 45’, 18 Gauge, Switch Box to Enclosure A Controller

with Pigtail

046059 1

7. Switch, Mini Series, Clip panel Mount, 12V, Green 306406 2

8. Switch, Mini Series, Clip Panel Mount, 12V, Red 306407 1

9. Switch Rocker, (ON) OFF (ON), Quick Connect 306408 1

10. Switch, Hole Plug, Mini Series, Clip Panel Mount, Black 306409 2

11. Cable 60’, 18 Gauge to Water Level Sensor 046088 1

12. Fuse, Blade 5 Amp (Solenoid Box Controllers) 306525 4

13. Fuse, Max 50 Amp (Solenoid Box) 306384 1

14. Ground Speed Sensing **Serial No. & Revision Specific 306530 1

a. GPS Junction Box 306419 1

b. GPS With Cable & Plug Assembly 306420 1

c. Cable Assembly, LIN 10’ 046380 1



4-3



4-2

E. MONITOR SUPPORT PARTS GROUP


1. Joint Rebuild Kit 305141 1

2. Electric Monitor ** MSC/MST Serial No. Specific Part

a. Motor, Electric 304618 1

3. Hydraulic Monitor ** MSC/MST Serial No. Specific Part

a. Motor, Hydraulic 304656 1

b. Solenoid Valve (Monitor Control Valve Assembly) 304858 1

c. Solenoid Coil (Monitor Control Valve Assembly) 304859 2

C. WATER PUMP PARTS GROUP (M-3)


15. M-3 Pump Station ** MSC/MST Serial No. Specific Part (QCA) 304954 1

16. Packing, 3/8”, Set of 4 rings, M-3 Pump 304967 3

17. Shaft Assembly 304955 1

18. Seal, Grease 304960 2

19. Ring, Snap 304957 1

20. Ring, Thrust 304956 1

21. Key, Impeller 304962 2

22. Coupling 305102 1

23. Screw, Set 305107 2

24. Key, Coupling, M-3 Pump 305101 1

25. Seal, Volute, M-3 Pump 304973 1

26. Bolt, Impeller, M-3 Pump 304972 1

27. Washer, Lock, Impeller, M-3 Pump 304971 1

28. Washer, Impeller, M-3 Pump 304970 1

29. Wear Sleeve, M-3 Pump 304961 1

30. Packing Gland, Set 304969 1

31. Stud, Packing Gland 304966 2

32. Nut, Packing Gland 304757 4



4-3

C. WATER PUMP PARTS GROUP (M-4)


33. M-4 ** MSC/MST Serial No. Specific Part (Quick Change Assembly) 304991 1

34. Ring Packing, Shaft Seal 305114 3

35. Shaft Kit ** MSC/MST Serial No. Specific Part 305403 1

36. Seal, Grease 304960 1

37. Nut, Shaft 305630 1

38. Washer, Tab 305631 1

39. Key, Impeller 305106 2

40. Coupling 305102 1

41. Screw, Set 305107 2

42. Seal, O-ring, Volute 305111 1

43. Wear Ring, Frame 305091 1

44. Wear Ring, Volute 305092 1

45. Washer, Impeller 305093 1

46. Nut, Impeller 305627 1

47. Pin, Roll TBD 1

48. Packing Gland, Set 305098 1

49. Slinger 305100 1

50. Stud, Packing Gland 305105 2

51. Nut, Packing Gland 350228 4

1. Motor, Hydraulic (M75 20-7) ** MSC/MST Serial No. Specific Part 1

2. Seal Kit, (M75) 300944 1

3. Flow Control Valve 300161 1

F. MISCELLANEOUS PARTS GROUP


1. Valve, Butterfly, 3” 300030 1

2. Valve, Gate, 1.5” (Spray Bar) 300106 1

3. Valve, 3/4" Ball (Spray Bar) 300627 2

4. Seal, Coupling, 4” Dresser 300820 2

5. O-Ring, #24 (Split Flange) 354816 20

scheduled/special inspections & recommended support parts · 2013-05-28 · scheduled/special...

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